Luminaire with pre-assembled light engine and lens

Abstract

A luminaire includes a housing and a light engine. The light engine is detachably secured to the housing and includes a lens and an optical tray. The lens has a top surface, a bottom surface, and a peripheral edge. The top surface of the lens define a lens cavity. The optical tray is supported by the lens within the lens cavity.

That which is claimed is: 
     
       1. A luminaire comprising:
 a housing; and 
 a light engine detachably secured to the housing, the light engine comprising:
 a lens having an outer surface and an inner surface separated by a peripheral edge, the inner surface defining a lens cavity, and 
 an optical tray comprising a base comprising a mounting surface, a perimeter edge, and at least one light source provided on the mounting surface, wherein the optical tray further comprises an upstanding flange along a first portion of the perimeter edge and a downwardly extending flange along a second portion of the perimeter edge, wherein the upstanding flange extends in an upward direction relative to the base and the downwardly extending flange extends in a downward direction relative to the base, and wherein the optical tray is supported by the lens within the lens cavity such that the base and the at least one light source are within the lens cavity and recessed relative to the peripheral edge. 
 
 
     
     
       2. The luminaire of  claim 1 , wherein the at least one light source comprises LEDs, and wherein the LEDs are provided on the mounting surface of the optical tray. 
     
     
       3. The luminaire of  claim 1 , wherein the mounting surface of the base of the optical tray is a bottom surface of the base, and wherein the base of the optical tray further comprises
 a top surface, 
 wherein the the upstanding flange extends in the upward direction relative to the top surface of the base. 
 
     
     
       4. The luminaire of  claim 3 , wherein the upstanding flange comprises at least one slot and wherein the housing comprising at least one fastener that engages the at least one slot. 
     
     
       5. The luminaire of  claim 3 , wherein the upstanding flange is a first upstanding flange, wherein the optical tray further comprises a second upstanding flange along a third portion of the perimeter edge, and wherein the second upstanding flange extends in the upward direction relative to the top surface of the base. 
     
     
       6. The luminaire of  claim 5 , wherein the second portion of the perimeter edge of the base comprising the downwardly extending flange is between the first upstanding flange and the second upstanding flange. 
     
     
       7. The luminaire of  claim 6 , wherein the downwardly extending flange comprises a lip defining a notch, wherein the inner surface of the lens defines a ledge having a ledge surface and a tab, and wherein the optical tray is positioned within the lens cavity such that the tab is engaged with the notch. 
     
     
       8. The luminaire of  claim 7 , wherein the lip is positioned on the ledge surface. 
     
     
       9. The luminaire of  claim 1 , wherein the inner surface of the lens defines a ledge having a ledge surface within the lens cavity, and wherein at least a portion of the optical tray rests on the ledge surface such that the optical tray is supported by the ledge. 
     
     
       10. The luminaire of  claim 9 , further comprising an adhesive interposed between at least a portion of the ledge surface and the at least portion of the optical tray to secure the lens and optical tray together. 
     
     
       11. The luminaire of  claim 1 , wherein the housing comprises:
 an inner surface; and 
 an outer surface, 
 wherein the inner surface defines a housing cavity, and 
 wherein the light engine is positioned at least partially within the housing cavity. 
 
     
     
       12. The luminaire of  claim 11 , further comprising a gasket positioned between the light engine and the housing. 
     
     
       13. A light engine comprising:
 a lens having an outer surface, an inner surface, and a peripheral edge extending around a perimeter of the lens and separating the outer surface and the inner surface, wherein the inner surface of the lens defines a lens cavity, wherein the inner surface defines a ledge within the lens cavity that is recessed relative to the peripheral edge, and wherein the peripheral edge defines an opening providing access to the lens cavity; and 
 an optical tray comprising a base, wherein the base comprises a mounting surface for at least one light surface and a perimeter edge, wherein the optical tray further comprises an upstanding flange along a first portion of the perimeter edge and a downwardly extending flange along a second portion of the perimeter edge, wherein the upstanding flange extends in an upward direction relative to the base and the downwardly extending flange extends in a downward direction relative to the base, and wherein the optical tray is positioned at least partially on the ledge of the lens within the lens cavity such that the mounting surface is within the lens cavity. 
 
     
     
       14. The light engine of  claim 13 , wherein the mounting surface is a bottom surface of the base of the optical tray, wherein the downwardly extending flange extends in a downward direction relative to the bottom surface of the base and comprises a lip, and
 wherein the lip is positioned on the ledge of the lens. 
 
     
     
       15. The light engine of  claim 14 , wherein a notch is provided in the lip and a rib is provided on the lens and wherein the rib engages the notch when the lip is positioned on the ledge of the lens. 
     
     
       16. The light engine of  claim 13 , further comprising an adhesive interposed between at least a portion of the ledge and a portion of the optical tray to secure the lens and optical tray together. 
     
     
       17. A method of assembling a luminaire comprising:
 pre-assembling a light engine by securing an optical tray to a lens such that the optical tray is supported by the lens, wherein a base of the optical tray comprising a mounting surface for at least one light source is within a lens cavity, wherein at least one light source of the optical tray is mounted on the mounting surface and within the lens cavity, wherein the optical tray further comprises an upstanding flange along a first portion of a perimeter edge of the base and a downwardly extending flange along a second portion of the perimeter edge, wherein the upstanding flange extends in an upward direction relative to the base and the downwardly extending flange extends in a downward direction relative to the base; and 
 detachably securing the light engine to a housing by engagement between the lens and the housing. 
 
     
     
       18. The method of  claim 17 , wherein securing the optical tray to the lens comprises at least partially positioning at least a portion of a flange extending from the optical tray on a ledge defined within the lens cavity. 
     
     
       19. The method of  claim 17 , wherein detachably securing the light engine to the housing comprises:
 at least partially positioning the light engine within a housing cavity defined by the housing; and 
 detachably engaging first fasteners positioned within the housing cavity with a slot defined in a side flange of the optical tray. 
 
     
     
       20. The method of  claim 19 , wherein detachably securing the light engine to the housing further comprises securing second fasteners located on one of the housing or the lens with recesses located on the other of the housing or the lens, wherein the second fasteners are positioned on an exterior of the luminaire.